Troubleshooting Guide
Diagnose It. Fix It. Get Back Spraying.
Step-by-step troubleshooting for Intelli-Spray remote-control spray systems, retractable hose reels, and pump systems — covering the most common field issues and their solutions.
Critical: Start-Up & Shutdown Procedure
If your unit has an electric start, it must never be pull-started under any circumstances. Pull-starting an electric start unit can permanently damage the radio control board.
If an electric start unit will not start, do not attempt to pull-start it — recharge or replace the battery before use. For reliable power, we recommend wiring the unit to the host vehicle via a fused Anderson plug connection.
- Electric start units: always start electrically — never pull-start
- Manual start units: follow the start-up procedure in your operator manual
- When shutting down, turn the radio OFF first, then stop the engine
Radio Electrics & Reel Troubleshooting
My machine won't power on at all — where do I start?
Before anything else, check:
- Battery voltage — should read approximately 12.5–12.8V.
- Inline fuse on the thin red wire near the positive battery terminal — look for corrosion, melting, or damage and replace if needed.
A blown or corroded fuse is one of the most common causes of total system failure.
The reel won't retract using either the remote OR the manual button
- Confirm the machine battery is fully charged.
- Check the inline fuse on the red wire from the positive battery terminal.
- If the fuse is intact, remove the on/off toggle switch behind the weather shroud. Disconnect the two wires and briefly short them together. If the system powers up, the toggle switch is faulty and needs replacing.
The reel won't retract with the remote, but works from the manual button
- Replace the remote battery first (216-9V).
- Check the radio board — if indicator lights are on, verify the dip switch settings match the remote exactly.
- If coding is correct, you likely have a stuck relay — common after high humidity or long storage. While holding the remote button, gently tap the black relay with the handle of a screwdriver.
- If the reel still doesn't activate, the radio unit needs to be returned for diagnosis and repair. Contact our service team via the form below.
Radio board lights are on and coding is correct, but the reel won't respond
This is almost always a stuck relay — particularly common after humidity or extended inactivity.
- Press the remote button and gently tap the black relay with a screwdriver handle. This may free it temporarily.
- The relay should be replaced to prevent recurrence. Relays are soldered to the board and are replaceable with standard parts from auto parts stores.
The system stopped working after sitting unused for a long period
Likely causes include moisture buildup inside the unit, corrosion on fuses or relays, or electrical components degrading during long-term storage.
Prevention: Keep units sealed and dry. Check fuses, relays, and connections before restarting after any extended storage period.
The reel only retracts at close range
Work through these checks in order:
- Discharged transmitter battery — replace (216-9V). Replace every 3 months as routine maintenance.
- Aerial broken or loose on base — replace or tighten. Finger tight only — over-tightening will break the coax cable inside the aerial base and reduce range to as little as 20–40 metres.
- Coax broken inside aerial base — replace the aerial base and coax cable.
- Low 12V on machine — charge or replace battery. 12.5V allows optimum performance.
- Faulty receiver or transmitter — contact our service team for a radio return form.
- Interference from overhead power lines — relocate the spray system.
Can I use a different antenna on my Intelli-Spray?
What is the range of the remote control?
Can two Intelli-Spray units interfere with each other?
The reel rewind speed is too slow
- Engine revs too low — increase to ¾ throttle or approximately 2400 RPM.
- Drive belts slipping — adjust using the belt tensioner.
The reel is hard to pull out
Can I upgrade from a 27 MHz system to 915 MHz?
Pump & Pressure Controller Troubleshooting
The oil in my pump has turned white or milky
White or milky oil means water has entered the oil system through one or more perforated diaphragms. Continuing to use the pump will cause seizure and require full pump replacement. The pump must be fully rebuilt with new diaphragms, O-rings, and seals. Contact our service team for assistance.
I have water visible in the oil glass
Water in the oil glass indicates ruptured pump diaphragms. Running the pump further will seize it. Contact our service team immediately.
My sprayer had good pressure, then suddenly lost it
In most cases a damaged diaphragm in the pressure controller is the cause. To inspect, remove the four bolts securing the pressure controller and check the diaphragm for tears, perforations, or swelling. Any of these require diaphragm replacement.
If the diaphragm looks intact but pressure is still lost, check for a blocked strainer, air being drawn into the pump, or failed internal pump valves.
No pressure — good flow from by-pass back to tank
- Regulating valve not set for pressure — set lever (8) to "press" and adjust knob (6).
- Damaged or worn seat or spring in regulator — replace with Sting repair kit or new spring.
- Sticking pressure regulator slide — remove slide and lubricate with marine grease.
- Spray nozzles worn, missing, or exceeding pump capacity — replace with appropriate size.
No pressure — irregular flow from by-pass to tank
- One or more valves not seating — clean or replace valves.
- Air being drawn through suction line or filter — examine and repair.
- Air not fully evacuated from pump — run pump with lever (8) on by-pass until all air clears.
- Blocked suction filter or closed valve — clean filter or open ball valve.
- Drive belts loose, broken, or direct coupling damaged — tension or replace belts; replace coupling sprockets and chain.
- Ruptured hoses or fittings — repair or replace.
Pump delivering insufficient pressure — hoses are jumping
- One or more valves not seating — clean or replace valves.
- Diaphragm split (oil will go milky) — STOP PUMP IMMEDIATELY and replace diaphragm. Refer to pump manual.
- Air not fully evacuated — run pump on by-pass until clear.
- Air being drawn through suction line or filter — examine and repair.
- Oil level low — top up with 20W/30.
Pump delivering insufficient pressure — hoses are NOT jumping
- Damaged or worn seat or spring in regulator — replace.
- Sticking regulator slide — remove and lubricate with marine grease.
- Spray nozzles worn, missing, or exceeding pump capacity — replace with appropriate size.
- Main drive belts slipping — tension or replace; check coupling sprockets and chain.
- Leaking hoses or fittings — repair or replace.
My pump is noisy
- Oil level low — top up with 20W/30.
- Air in pump or being drawn through suction line — examine and repair.
- Blocked filter — clean filter.
Water returning to tank through the safety valve hose
What oil do I use in my pump?
Can I run diesel through my Intelli-Spray?
Submit a Service Enquiry
If this guide hasn't resolved your issue, complete the enquiry form with a detailed description of the problem — including your system model, pump type, and what you've already tried. Our technical team will respond within 1 business day.
Responding within 1 business day. For urgent issues during business hours, call +1 (469) 949-5786 or email info@intelli-spray.com. Operating hours: Mon–Thu 8am–4pm, Fri 8am–3pm AEST.